Method of making molds for chains



PI 25, 1950 c. E. sENNHoLTz r-:TAL 2,505,507

METHOD 0F MAKING MOLDS FOR CHAINS Filed Oct. 17, 1947 5 Sheets-Sheet 1.

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Charles El Senn@ Carlo's .E Anderson April 25, 1950 c. E.l SENNHoLTz ET AL 2,505,507

METHOD OF MAKING MOLDS FOR CHAINS Filed Oct. 17, 1947 5 Sheets-Sheet 2 3% mi? "5&5 f 4Q Q2 4Q y l @e 72/ 7 Z im 65 e5 rif 6,5 55

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METHOD 0F' MAKING MOLDS FOR CHAINS Filed Oct. l?, 1947 5 SheeS-Sheet -5 Charles E. 59222219 Carlos E. Anderson 62W... Aaa-f v adx/v Prin 25, 1950 c. E. sENNHoLTz ETAI. 2,505,507

METHOD 0F' MAKING MOLDS FOR CHAINS Filed OCT.. 17, 1947 i: .a5 .6' a@ Gf Si@ JV* 5 Sheets-Sheet 4 /-OIQS Charles E Sermhofg Carlos E. Anderson LQTTonNaY-f April 11 1950 c. E. sENNHoLTz ETAL 2,505,507

METHOD OF MAKING MOLDS FOR CHAINS Filed Oct. 17, 1947 5 SheetS-Sheeb 5 /W "I l? l\ /I MTC@ Charles E. Seng@ Carlos E. Anderson www Mg@ r-ronNsYJ Patented pr. 25, i950 METHOD F MAKNG MOLDS FUR CHAINS Charles E. Sennholtz and Carlos E. Anderson, Chicago, Ill.; said Anderson assignor to said Sennholtz Application Gctober 17, 1947, Serial No. 780,330

9 Claims. l

The present invention pertains generally to the manufacture of chain in sections of any desired length. More particularly, it is concerned with an improved casting process for placing cast chain upon a comparable competitive plane with chain made by other processes.

One of the objects of the invention is to provide an improved method of casting chain involving the use of one or more simple bench molds of refractory material whereby a section of any predetermined length may be cast at one pouring.

Another object is to provide an improved method of casting chain wherein simple, inexpensive core inserts are utilized and the use of precast links is dispensed with.

A further object is to provide an improved and reliable arrangement for casting chain and which will be more economical than methods in use heretofore.

Other objects and advantages of the invention will become apparent as the following descrip tion proceeds and from the accompanying drawings, in which:

Figures 1 and la illustrate the preparation oi core inserts for the respective halves of a mold.

Figs. 2 to 4 are transverse sectional views taken at successive steps in the preparation of the lower or drag half of a mold.

Figs. 2a and 3a are transverse sectional views taken at successive steps in the preparation of the upper or cope half of a mold.

Fig. 5 represents a transverse sectional view taken through a completed mold.

Fig. 6 illustrates an endtoend arrangement of molds for casting a continuous length of chain.

Fig. 7 is a longitudinal sectional view through one of the core insert boxes.

Fig. 8 is a transverse sectional View through the box of Fig. 7 and taken in the plane of the Eine 8-8.

Fig. 9 is a perspective view of the core insert prepared for use in the drag half of the mold.

Fig. 10 is a longitudinal sectional view through the molding box for the drag half of the mold.

Fig. 11 is a transverse sectional view taken in the plane of the line ll--ll in Fig. 10.

Fig. 12 is another longitudinal sectional view through the molding box for the drag half but with the removable pattern for the lower halves of the upright links in place.

Fig. 13 is a longitudinal sectional view through 2 the completed drag half of the mold with the core insert installed.

Fig. 14 is a perspective View of the completed drag half of the mold inverted and in position to receive the cope half.

Fig. 15 is a longitudinal sectional view through the second core insert box and showing the detachable gate blocks.

Fig. 16 is a transverse sectional view of the box of Fig. 15 taken in the plane of the line i6|6.

Fig. 17 is a perspective view of the core insert prepared for use in the cope half of the mold.

Fig. 18 is a longitudinal sectional view through the molding box for the cope half of the mold and indicating the relative locations of the head and gate blocks.

Fig. 19 is a transverse sectional view taken in the plane of the line |9 l9 of Fig. 18.

Fig. 2O is another longitudinal sectional view through the molding box for the cope half but with the removable pattern for the upper halves of the upright links in place.

Fig. 21 is a longitudinal sectional View through the completed cope half of the mold, with the core insert installed.

Fig. 22 is a perspective view of a completed mold assembled and in condition to receive poured metal.

While the invention is susceptible of various modifications and alternatives, a preferred mode of carrying out the invention has been described in some detail. but it is to be understood that there is no intention to limit the invention to the specific process disclosed, the intention being, on the contrary, to cover all modiiications and alternative methods falling within the spirit and scope of the invention as expressed in the appended claims.

Referring to the drawings, an exemplary mode of carrying out the invention is illustrated in connection with the manufacture of stud link chain, which is a type wherein each link is constructed with a transverse strut to increase its strength by resisting stresses tending to collapse the link. It will be observed that the method described may conveniently be practiced through the use of certain standard foundry equipment such as bench molding boxes 30 and 3i, each having a set of patterns 32. 34 mounted therein, together with a pair of core boxes 35, 36. These items are utilized to produce one or more core-like bench molds of refractorzs7 material, each mold comprising a lower or drag half 38 and an upper or cope half 39.

To begin with, the process embodying the invention entails the preparation of a pair of elongate, complementary core inserts 40, 4l. shown in Figs. 9 and 17, for the drag and cope halves of the mold respectively. This is accomplished by filling the core'boxes 35 and 36 With core sand or similar refractory material, ramming the latter into a compact mass, and then removing any excess projecting above the plane of the top of each box. Theboxes and 36 are then inverted, permitting the cores 4l) and 4l to be removed therefrom inorder'tobe dried, the removal being facilitated by thernecesjust suiiicient to permitordinary handling with negligible riskof breakage.

Figs. '7 and 15 show a series ofblocksspaced along the bottoms-of thecore boxes 35 and S5. Included in each series is a large, centrally located, curved block 42 representing the outer ii.

contour of half a link of chain 'andiianking .the later on either side -is a-smaller, curved block '4d representing the outer contour-,of a quarter link of chain. Between'thezblocks 42 and@ but sep arated therefrom, are a pair of small wedgeshaped blocks 45 of a size and shape equivalent to the external contour of :half of one .of the link struts. By reason of the foregoing arrangement within the core boxes, each of the core'inserts 4U, 4l is given a bridge-like appearance comprising an elongated Vhorizontal portion i5 and a pair of spaced-apartdepending abutments 48 which have wedge-shaped lateral notches at their lower ends. Turning again to Figs. 9 and 17, it will be noted that'underedges or undersurfaces 50 formed in thefcoresiiilfand il 'by the blocks 42 and AMfhave lateral as well as'longitudinal-curvature, beingcontoured in conformity to the outer peripheral surfaces of a set or group of alined, alternate, chain links which, for purposes of description, .will `be called the upright links as distinguished from another setfcalled'the horizontal links.

ABrovision is made forenabling themolder `to accurately position the core insert 40 `within the moldand to preclude axial sliding of the `insert when so positioned. Thus .the core lil is shaped intermediate its ends and on -one .side of the portion 46 with a tapered shear lug 5! (see Figs. '7 to 9) molded in a cavity 52.011 one ofthe inner sides ofthe corebox 35.

'By reference to Figs. 15 to 17, it will be seen that the core 4I .is formed with double shear lugs 54 located at its center and also witha shorter pair of such lugs `55 disposed adjacent each end. These lugs are produced by the cavities 56, .58 .in the sides of the core box 36 and serve the same purposes as the single flug 5l on the core 4D. In addition, theyprovide'the necessary added width to Iallow for the incorporation into the core 4i of gate passages EQ, Sil extending downwardly from the exterior to the undersurfaces d and terminating at the latter. The passages 59, 5t are formed by the simple expedientof mounting detachable gate blocks 5l, 62 on the blocks 42, 44 of the core box 36 prior to filling the same with core material.

The core inserts having been completed, the complementary halves 38, 49 of the mold must now be prepared. While this maybe accomplished in a variety of ways, for example by the use of conventional molding flasks, together with double faced match-plates or with molding boards having detachable split patterns, it has been found preferable to utilize, for each half of the mold, separate molding boxes resembling core boxes and having their inner surfaces contoured to correspond to the vimpressions which must be reproduced in the mold.

Considering first the molding box 3@ for the bottom or drag half 38 of the mold, and which will behereafter referred to as the drag box, the sameis shown in Figs. 10 to l2 comprising a generally rectangular, open-topped box having a 'floor 'or bottompanel 54. The latter of course defines the upper face of the drag half "iii of the mold. Disposed along the panel 64 and rigidly secured thereto in carefully spaced relationship between themselves and the sides of the box 3i are a pair of split patterns 65 representing cavities to be formed along the vupper face of the drag half 38 and corresponding to the bottom halves vof a set of alternate chain links `which will be `called the horizontal links. The latter serve to connect the other alternate or upright linksalready mentioned. Adjacent each of the patterns 65 and centrally located with reference thereto are a pair of blocks iifor forming the bottom portions 68 of mold head chambers Sil- Which are indicated in Fig. 22.

vMeansis provided for forming in the respective mold halves a plurality of properly spaced impressions corresponding to the inner peripheral surfaces of the upright links and isolated from the horizontal links impressions. For this purpose, -an additional pattern lil (see Fig. 12) is mounted in the drag box 3E! longitudinally thereof and centered by means of unitary end tongues ll. The latter are slidably received by tapered vertical keyways l2 centrally located in the inner faces of the short sides of the box 36. In the present instance thepattern l@ presents a bridgelike appearance similar to that of the core insert 40 except for the fact that the arched undersurfaces 'I4 of the former are laterally convex rather than concave, being contoured in conformity to the inner peripheral surfaces of the upright links. A 'further difference resides in the fact that the Vpattern l?) is also provided with vertically disposedstruts l5 and 'iii representing the strut or stud pieces of the upright links.

With the drag box Sil in the condition described, the same is thereupon filled with refractory mold material which may be core sand or an appropriate alternative therefor. This material may be rammed either manually or by machine until it has Iacquired the proper compactness at which time the excess projecting above the top of the box is scraped off. As indicated in Fig. 12, this results in the creation of complete impressions in the face of the drag half 38 lof 'the mold for the bottom halves or" the horizontal links, and also partial impressions in the body of the drag half 38 for the bottom f halves of the upright links and corresponding to the inner peripheral surfaces thereof.

At this point, the pattern it, which has been formed with sufficient draft or taper to permit easy removal, is withdrawn from the drag half of the mold. In addition to the chain link surface impressions already mentioned, this pattern has left in the mold half 38 core prints adapted to raccurately receive the core insert 4i] and to retain the same positively against both axial and ltransverse movement. The latter is then mounted in the drag half by insertion from the exterior rather than from the face thereof, and when mounted as shown in Figs. 3 and 13 completes the impressions or -cavities for the bottom halves of the upright links. With the core insert 40 securely in place, the drag box is inverted (see Figs. 4 and 14) and removed from the drag half 38 of the mold. The latter is dried in the inverted or face-up position preparatory to receiving the cope half 39.

Turning now to Figs. 2a, 18 and 19, it will be noted that the cope half 39 of the mold is prepared by the use of similar apparatus and in a manner resembling that utilized for the drag half. In the present instance, however, patterns 'I8 on iloor panel 'I8 of the cope box represent the upper halves of the cavities for the horizontal links. Adjacent the link patterns 'i8 are head blocks 80 which serve to create impressions in the mold for the head cavities 69, thus insuring a steady ilow of metal to the link cavities when the mold is poured. In order to provide a connecting passage between the head cavities 69, an elongated block 8i is mounted on the panel 'I9 between the head blocks S0. Intermediate the ends of the block 8! and rising vertically therefrom is a gate block 82 which produces an impression constituting the passage through which the molten metal for the horizontal link cavities enters the completed mold. As shown in Figs. 2a and 20, an additional pattern Si resembling the pattern 'IU for the drag half and mounted in the same manner is employed to form impressions representing the upper halves of the inner peripheral surfaces of the upright links and at the same time to make a core print for receiving the core insert lll. Thus when the cope box 3| is lled with core material and rammed, complete impressions are formed in the face of the cope half 39 for the upper halves of the horizontal links, together with partial impressions in the body of the cope half for the upper halves of the upright links and corresponding to the inner peripheral surfaces thereof. Removal of the pattern all and substitution of the core insert 4i, which, like the insert llil is mounted by insertion from the exterior of the mold half 39, completes the impressions for the upper halves of the upright links. The cope half 39 of the mold is thereupon removed from the cope box and dried in the face-down position preparatory to assembly with the drag half 38.

For the purpose of obtaining accurate registration between the impressions in the drag and cope halves of the mold, provision is made for interlocking the latter upon assembly. Thus the drag boX 3D is constructed with a pair of narrow, tapered ribs 85 running along the intersection between the longer sides and the panel 6i, and overlapping slightly along the intersections between the shorter sides and the panel. This produces a pair of tapered locking grooves 86 in the drag half 38. Conversely, the cope box 3l is provided` with a pair of complemental grooves B8 of corresponding size to the ribs 85 and producing, in the completed cope half 39, a pair of ribs 89 fitting closely into the grooves 8E. The mating impressions resulting from this construction constitute a secure interlock between both halves of the mold (see Figs. 5 and 22), retaining the same against relative movement in both the lateral and the longitudinal directions.

Upon the completion of a pair of mold halves as already described, the same are assembled together face to face so as to constitute a unit bench mold as shown in Fig. 22. This causes certain of the respective impressions in the mold halves to register and thus maintain the latter in interlocking engagement, at the same time causing other impressions to register and form complete mold cavities in the shape of enchained links which are ready to receive molten metal.

As Can be appreciated by reference to Fig, 6, a chain of any predetermined length may be cast at one pouring merely by placing a plurality of unit bench molds together in alined end-toend relationship. With such an arrangement, the mold cavities adjacent the ends of the unit molds are brought into registration, thereby forming from mold to mold a continuous series of enchained link cavities corresponding in size and shape to the length of chain to be cast. Since the molds are made in precisely constructed core boxes and dried uniformly, any number of molds can be matched in the foregoing manner. Thus it becomes possible to bring the ends of adjacent molds together with such accuracy and closeness that chain links cast half in one mold and half in the next mold will be as uniform as those cast entirely within a single mold.

Pouring of one mold or a series thereof may be accomplished in a single operation although separate sets of gate passages are utilized to conduct the molten metal to the respective sets of alternate link cavities. For example, the cavities representing the horizontal links received poured metal through gate passages sti in the cope half of each mold such passages being' shown in detail in Figs. 3a and 5 where the upper left hand corner of the cope section is broken away for purposes or" illustration. to expose the interior of its passage Sii. The cavities for the upright links, on the other hand, receive metal through the gage passages 5@ and 6G in the core inserts 4'! We claim as our invention:

l. The method of casting chain which includes the steps of forming a pair of complementary core inserts one of which has downwardly extending gate passages terminating at the undersurfaces thereof, forming drag and cope halves of a mold by means of patterns creating mold cavities along their respective faces and by means of additional patterns creating mold impressions and core prints in the respective body portions of said drag and cope halves, the cavities vformed lby said split patterns corresponding to one set of alternate chain links and the mold impressions formed by said additional patterns corresponding to the inner peripheral surfaces of a second set of alternate chain links, the cope half of said mold also having at least one gate passage therein, respectively installing each of said core inserts in the core print in each of the halves of said mold to complete the impressions for the second set of alternate links, assembling the drag and cope halves of said mold together so that the link impressions and the core inserts therein register to form a series of separate enchained. cavities in the mold in the shape of said sets of alternate chain links, pouring metal into the cavities for said one set of alternate links through the gate passage .in the cope half of the mold, and pouring metal into the cavities for said second set of alternate links through the gate passages in said one of said core inserts.

2. In a method of casting chain, the steps which comprise forming for the complementary halves of a mold apair of elongate, bridge-like core inserts one of which has pouring gate passages connecting its exterior and undersnrfaces, preparing the halves of said mold by means of patterns .adapted to make complete impressions therein 'corresponding to one set of alternate chain links together with pouring gate passages therefor and by means of additional patterns adapted to make partial impressions representing a'second set of alternate chain links, said additional patterns also being adapted to make core prints in said mold halves for receiving said core inserts, installing each of said inserts respectively in the core prints of the mold halves to complete the impressions for the second set of alternate'links, assembling'together the halves of said mold with proper registration between corresponding impressions for said sets of links so as to form a series of enchained cavities in the shape of complete chain links, and pouring metal into the cavities through the gate passages in said mold halves and said core insert.

3. In a method of casting chain, the steps comprising forming a pair of elongate core inserts for the complementary halves of a mold, preparing the halves of said mold by means of one set of patterns adapted to form complete impressions corresponding to one set of alternate chain links and by means of another set of patterns adapted to form core prints for said elongate cc-re inserts as well as partial impressions for a second set of alternate chain links, installing each of said inserts respectively in the core prints of the mold halves to complete the impressions for the second set of alternate links, and assembling the mold halves to form a mold having a series of separate enchained cavities therein.

4. In a method of casting chain, the steps which include forming a pair of core inserts each for use with a respective half of a mold and having surfaces constituting a portion of each of the mold cavities for a set of upright chain links, forming drag and cope halves of a mold by the use of patterns adapted to create impressions in the faces thereof corresponding to a set of horizontal links alternating with the upright chain links and also forming said drag and cope halves by the use of additional patterns adapted to create the remainder of each of the mold cavities for said upright links, said additional patterns also being adapted to create core prints in said halves for receivingl said respectiY e core inserts and retaining the same positively against axial and transverse movement, installing said respective core inserts in said drag and cope halves of said mold from the exterior thereof, and assembling said cope and drag halves toform a mold having a series of separate enchained cavities therein.

Y5. The method of casting a continuous length of chain and which comprises forming two complementary series of core inserts, those of one series having gate passages at and intermediate their ends and connecting the exterior and undersurfaces thereof, preparing by means of appropriate patterns a plurality of molds each having drag Vand cope halves with impressions therein corresponding to one set of alternate chain links and core prints therein correspondin part to a second set of alternate chain links, one set of patterns being used for said impressions and another set for said core prints, installing' said core inserts in respective core prints in said drag and cope halves of each mold thereby-completing the impressions for said second set of Lli) alternate chain links, assembling respective mold halves so that the impressions therein-and the core inserts register to form a series of separate enchained cavities in each mold, arranging the assembled molds inend-to-end relationship with the gate passages and cavities adjacent the mold ends in registration to form a continuous series of enchained cavities from mold to mold, and pouring metal into the cavities of each mold.

6. The method of casting a continuous length of chain and which comprises forming two complementary series of core inserts, those of one series having downwardly lextending gate passages at and intermediate their ends and terminating at the undersurfaces thereof, making lby means of appropriate patterns a plurality of molds each having drag and cope halveswith impressions in the faces thereof corresponding to one set of alternate chain links and core prints in the bodies thereof corresponding in part to a second set of alternate chain links, one setoi patterns being used for said impressions and another set being used for said core prints, the cope halves of said lmolds also having gate passages communicating with the impressions for said one set of alternate chain links, respectively mounting a core insert from each series in the core print in each of said mold halves thereby completing the impressions for said second se't of alternate links, assembling together respective mold halves so that the impressions therein and the core inserts register to form a seriesof separate enchained cavities in each mold, arranging the assembled molds in end-to-end relationship with the gate passages and cavities formed by inserts adjacent the mold ends in registration to form a continuous series of enchained cavities from mold to mold, pouring metal into the cavities corresponding to said one set of alternate links through passages in the cope halves of the molds, and pouring metal into cavities corresponding to said second set of alternate links through the gate passages in said core inserts.

7. The method of producing cast chain which includes forming a pair of complementary core inserts each having undersurfaces contoured to conform to the outer peripheral surfaces of a group of alternate chain links, `forming drag and cope halves of a mold about a set of patterns corresponding to alternate chain links connecting those of said groupand about another set of patterns each generally corresponding in sise and shape to a respective one of said core inserts but having undersurfaces contoured to conform to the inner peripheral surfaces of said group of alternate links, one pattern in said other set being used in the drag and one being used in the cope, removing each pattern of said other set from its respective half of said mold, respectively inserting one of said core inserts in the core print left in each half of said mold by withdrawal of said pattern from said other set, such insertion being done from the side away from the face of each half of said mold, and assembling said cope and drag halves to form a mold having a series of separate enchained cavities therein.

8. The steps in the method of producing cast chain which comprise forming a pair of complementary core inserts having underedge contours conforming to those of the outer peripheral surfaces of alternate chain links, forming drag and cope halves of a mold through the use of molding boxes and horizontally disposed patterns corresponding to chain links connecting atomo:

said alternate links and also through the use of vertically disposed patterns having edge contours conforming to those of the inner peripheral surfaces of said alternate links, withdrawing a vertically disposed pattern from each half of said mold leaving a core print therein, positioning a core insert in the core print in each half of said mold from the exterior thereof, removing from the molding boxes the respective halves of said mold and drying the same, assembling said mold halves with the impressions therein registering to form cavities in the shape of enchained links, and pouring molten metal into the mold.

9. The method of casting a continuous length of chain and which comprises molding in core boxes a plurality of pairs of elongate complementary core inserts having undersurfaces contoured in conformity to the outer peripheral surfaces of alternate chain links, drying said core inserts, preparing drag and cope halves for a plurality of molds by means of molding boxes and horizontally disposed patterns corresponding to chain links connecting said alternate links and also through the use of vertically disposed patterns having undersurfaces contoured in conformity to the inner peripheral surfaces of said alternate links, respective pairs of said mold halves also being formed with mating impressions for maintaining said mold halves in interlocked engagement when assembled together, withdrawing a vertically disposed pattern from each of said mold'halves leaving a core print therein, positioning a core insert in the core print in each of said mold halves; removing from the molding boxes the respective mold halves and drying the same, assembling together said cope and drag halves by pairs so that certain of the impressions therein register to form cavities in the shape of enchained links while others maintain said mold halves in interlocked engagement, arranging assembled molds end-to-end with the cavities adjacent the ends thereof in registration thereby forming from mold to mold a series of enchained link cavities corresponding to the continuous length of chain to be cast, and pouring molten metal into the cavities of said molds.

CARLGS ANDERSON.

CHARLES E. SENNHOLTZ.

REFER-ENCE S CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 390,907 Sage Oct. 9, 1888 769,959 Price Sept. 13, 1904 1,365,672 Fawcett Jan. 18, 1921 1,365,702 Knadler Jan. 18, 1921 1,398,706 Rust Nov. 29, 1921 OTHER REFERENCES Pattern making by Horner; 1902; pages 53, 54 and 71-77, inclusive.

Cast Metals Handbook by American Foundrymens Association; 3rd edition; 1944; picture on frontispiece and pages 14-17, inclusive. 

